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NetsureTM 702 IC4

DC Power System

User Manual

Emerson part No.

Revision

Revision Date

744802500508

00

Feb 23, 2015

Copyright 2009 by Emerson Network Power India Pvt. Ltd.


All rights reserved. The contents in this document are subject to change without notice.

Homepage: www.emersonnetworkpower.com

Head Office:
EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED
Plot No. C-20, Road No. 19,
Wagle Industrial Estate
Thane 400 604, Maharashtra, INDIA
Phone: (00 91 22) 33154400
Fax: (00 91 22) 25800829 / 25828358

NETSURE 702 IC4 Manual

Dear Customer,

Please accept our thanks for giving us the privilege to serve you by choosing Emerson make
702IC4 DCPS.

If this is your first Emerson 702IC4 DCPS, we hope it is the beginning of a long relationship which
delivers value to your organization. If you already own and use Emerson Product, we are doubly
honored by your decision of continuing this relationship.

It is our constant endeavor to partner you for the growth and success of your Business. This
philosophy is reflected in our Mission statement To deliver value through Air & Power Quality
solutions to achieve customer delight. Please do give us feedback to help us realize our Mission.

Emerson Network Power (India) Private Limited

NETSURE 702 IC4 Manual

IMPORTANT

This manual contains information concerning the installation, operation and maintenance of the
DC Power System.

All relevant parts of the manual should be read prior to commencing installation.
The DCPS must be commissioned by an engineer approved by the manufacturer (or his
agent) before being put into service. Failure to observe this condition will invalidate any
implied warranty.

The DCPS has been designed for Telecom use only.

The DCPS has not been designed for direct use in any life support application. If you encounter
any problem with the procedures contained in this manual, you should seek immediate
assistance from Emerson Network Power (India) Pvt. Ltd. Sales Office from whom the
equipment was purchased. Alternatively contact the Emerson Network Power (India) Pvt. Ltd
Customer Service & Support department at the address shown below:

EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED


Plot No. C-20, Road No. 19,
Wagle Industrial Estate
Thane (West) 400 604,
Maharashtra, INDIA
Phone: (00 91 22) 33154400

Customer Care / Service Helpline Number:


Toll Free: 1800 209 6070
Chargeable: +91-22-66231200

NETSURE 702 IC4 Manual

Safety Precautions
To reduce the chance of accident, please read the safety precautions very carefully before
operation. The "Caution, Notice, Warning, Danger" in this manual do not represent all the
safety points to be observed, and are only used as supplement to various operation safety
points. Therefore, the installation and operation personnel must be strictly trained and
master the correct operations and all the safety points before actual operation. When
operating Emerson products, the safety rules in the industry, the general safety points and
special safety instructions specified in this manual must be strictly observed.

Electrical Safety
I. Hazardous voltage

Danger
Some components of the power system carry hazardous voltage in operation; direct contact
or indirect contact through moist objects with these components will result in fatal injury.
Safety rules in the industry must be observed when installing the power system. The
installation personnel must be licensed to operate high voltage and AC power. In operation,
conductive objects such as watch, bracelet, bangle, ring, etc. are not allowed to be worn.
When water or moisture is found on the cabinet, turn off the power immediately. In moist
environment, precautions must be taken to keep moisture out of the power system.
"Prohibit" warning label must be attached to the switches and buttons which are not
permitted to be operated on during installation.

Danger
High voltage operation may cause fire and electric shock. The connection and wiring of AC
Cables must be in compliance with the local rules and regulations. Only those who are
licensed to operate high voltage and AC power can perform high voltage operations.

NETSURE 702 IC4 Manual

II. Tools

In high voltage and AC operation, special tools must be used. No common or self-carried
tools should be used.

III. Thunderstorm

Danger
Never operate on high voltage, AC, iron tower or mast on a day with thunderstorm. In
thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the
equipment should be well earthed in time to avoid damage by lightning strikes.
IV. ESD

Notice

The static electricity generated by the human body will damage the static sensitive elements
on PCBs, such as large-scale ICs, etc. Before touching any plug-in board, PCB or IC chip,
ESD wrist strap must be worn to prevent body static from damaging the sensitive elements.
The other end of the ESD wrist strap must be well earthed.
V. Short-circuit

Danger
During operation, never short the positive and negative poles of the DC distribution unit of
the system or the non-earthing pole and the earth. The power system is constant voltage DC
power equipment; short circuit will result in equipment burning and endanger human safety.
Check carefully the polarity of the cable and connection terminal when performing DC live
operations.
As the operation space in the DC distribution unit is very tight, please carefully select the
operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Insulated tools must be used.
In live operation, keep the arm muscle tense, so that when tool connection is loosened, the
free journey of the human body and tool is reduced to a minimum.
NETSURE 702 IC4 Manual

Version history details of 744802500508_00- User Manual


For- Net sure 702 IC4

Following is the reference version history summary of all the revisions made in User Manual
for Net sure 702 IC4 Power System.

Version

Revision

Prepared

Reviewed

Approved

No.

Description

by

By

by

00

Initial

SKD

RY

RJ

NETSURE 702 IC4 Manual

Date

23-02-15

10

Contents
Safety Precautions

Chapter 1 Introduction

12

1.1 Features

12

1.2 Operation Theory

12

1.3 Lightning Protection

13

1.4 LLVD and BLVD

13

1.5 Alarm and Protection

13

Chapter 2 System Configuration

14

2.1 System Configuration

14

Chapter 3 System Components

16

3.1 R48-4000e Rectifier

16

3.1.1 Form and Interface

16

3.1.2 Main Functions and Features

17

3.1.3 Specifications

19

3.2 SCU M523S CONTROLLER

20

3.1.4 3.2.1 Dimensions and Structure

20

3.1.5 3.2.2 Main Functions

20

3.1.6 3.2.2.1 Different Authorities Protected by Different Password Levels

20

3.3 Operation Panel of the Controller

21

3.1.7 3.3.1 Power-on Sequence


Chapter 4 Installation & Commissioning Procedure

22
38

4.1 Pre-Checks for Installation

38

4.2 Accessories

38

4.3 Installation procedure

38

4.4 Wiring up the interconnection between Unit, Mains & Battery

39

4.5 General Functional Procedure

39

Chapter 5 Testing Procedure

40

5.1 Testing procedures

40

5.2 Resetting System

41

5.3 Testing AC Distribution

41

5.4 Testing Rectifier

41

5.5 Testing Monitoring Module

41

5.6 Testing Distribution Switches

41

5.7 Battery Connection

42

5.8 Load Connection

42

Chapter 6 System Specifications & General Requirements

43

6.1 Technical Specifications

43

6.2 Guideline for Earthing

43

6.3 System Input And Output Recomanded Connections

44

6.4 Recommanded Torque

44
NETSURE 702 IC4 Manual

11
6.5 List of Recommanded Spares

44

Chapter 7 Installation Preparation

45

7.1 Installation Requirements

45

7.2 Layout Requirements Of The Equipment Room

45

7.3 Power Supply

46

7.4 Safety Protection

47

7.5 Equipment Running Environment Checklist

48

7.6 Storage Conditions

48

7.7 Component Replacement Process

48

Chapter 8 Electrical Schematic

50

Dos

52

Donts

53

NETSURE 702 IC4 Manual

12

Chapter 1 Introduction
NETSURE 702 IC4 Power system consists of R48-4000W rectifiers, Standard Controller Unit
(M523S), AC distribution and DC distribution, which consist of distribution unit for load and
battery. The Load distribution and Battery Distribution units can be designed as per users
requirement. This system is used as a power supply for telecom equipment with system
nominal voltage of -48V and positive terminal earthed.

1.1 Features
The power system is easy-to-operate/install/maintain. Its main features are:
Rectifier uses APFC technology and therefore its power factor is up to 0.99
Wide AC input voltage range of 85~290V
Rectifier efficiency is >94% at the peak
Rectifiers compliant with UL, CE and NEBS standards
True hot pluggable, the replacement time is less than 1min
Perfect battery management with BLVD function
Up to 200 no of historical alarms
Provide RS232, Modem and dry contacts communication interfaces.

1.2 Operation Theory


The basic operating theory of power system is shown in the following figure:
Power cable
Signal cable
Figure 1-1 Basic operation theory diagram
Rectifier AC
Breakers

AC Input Terminals

Rectifiers

C Class SPD
Back Board

Control Unit

Battery 1

BLVD

LLVD
(Optional)

Non Prior Load

Prior Load

Battery n

AC mains inputs rectifiers through AC input terminals and rectifiers breakers. (The rectifiers
output to the priority load or to non-priority load through a LLVD, and output terminals of
rectifiers connect with batteries). Batteries connect to the loads through BLVD contactor. The
monitoring unit collects the working states of each part of the system and generates alarm to
alert users.
NETSURE 702 IC4 Manual

13

1.3 Lightning Protection


Net sure 702 IC4 Power System has perfect lightning protection on input side, as shown in
the following figure:
Rectifier
AC Input

I/B
SPD

5~10m

AC power
distribution
unit
II/C
SPD

DC power
distribution
unit

Rectifier

48V Output

DC
SPD

Rectifier

Battery
group
1/2

Monitoring
unit
RS232
RJ11

Note:
I, II, III are based on IEC standard
B, C, D are based on German VDE standard
DINVED0675-6: 1989-11 (draft)

PSTN

MODEM
RJ11
SPD

Remote monitoring host

Figure 1-2 AC lightning protection


A built-in II/C Surge Protection Devices (SPDs) is installed in the system, while each rectifier
is designed with perfect lightning protection circuits. The whole system can withstand 8/20s
surge current 20kA for 5 times, or 8/20s surge current 40kA once. To further protect the
system, Class I/B SPD which comes as optional item (with through current capacity of at
least 50kA) can be installed close to the main AC distribution board.

1.4 LLVD and BLVD


Batteries will start discharging to power loads once the AC mains fails. When the battery
voltage reaches to 45V (low voltage point, adjustable), the system will raise audible/visual
alarms. When the battery voltage continues dropping to 44.0V (LLVD point, adjustable), the
LLVD contactor will act to cut off power supply to non-priority loads (such as local exchange)
so as to ensure power supply to priority loads (such as transmission equipment).
As the discharge goes on, when the battery voltage drops to 43.2V (BLVD point, adjustable),
the BLVD contactor will act to cut off the connection between the batteries and the system,
stopping the power output and protecting the batteries. When AC mains recover, rectifiers
will resume outputs, LLVD & BLVD contactors will close automatically, and the system will
restore to normal operation.

1.5 Alarm and Protection


Based on the real-time data collected by the monitoring module, the system can detect the
states of output breakers, battery breakers and class II/C SPD. User can set the severity
level of faults such as AC input over/under-voltage, DC output over/under-voltage, etc. so as
to raise audible/visual alarms upon designated faults. User can also set alarm types of alarm
dry contacts.

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14

Chapter 2 System Configuration


2.1 System Configuration
The typical outline of Cabinet of NETSURE 702 IC4 is illustrated by the views in Figure 1-3.

Figure 1-3 System views


NETSURE 702 IC4 Manual

15

The cabinets can be configured with the following functional units and components:

Rectifier Rack can accommodate up to 3 rectifiers.

Monitoring module M 523S

NETSURE 702 IC4 Manual

16

Chapter 3 System Components


3.1 R48-4000e Rectifier
R 48 4000 e
HIGH EFFICIENCY
4000 W OUTPUT POWER

48 VOLTS DC OUTPUT
RECTIFIER
Figure 1-4: Model Number
3.1.1 Form and Interface

There are 3 indicators on the front panel. The location of the indicators is shown in
Figure1-5.

Figure 1-5: Front Panel


The functions of the indicators are listed in Table 1-1.
Table 1-1:Function of Indicators
Indicator

Normal state Fault state

Power indicator
(Green)

On

Protection indicator
(Yellow)

Off

Off

No input and output

Flashing

The rectifier is being operated through the host.


AC input under/over-voltage, rectifier PFC output
under/over-voltage, high-temperature, or current
sharing imbalance
Rectifier communication failure
Output over-voltage, output fuse blown, or rectifier
addresses contradictory
Faulty fan

On
Flashing

Fault indicator (Red) Off

Fault cause

On
Flashing

NETSURE 702 IC4 Manual

17

3.1.2 Main Functions and Features

1. Hot Swappable
The rectifier is designed to be plug-and-play. There will be no arcing and the terminals will
not be damaged when inserting/removing the rectifier from a live DC power system. A
rectifier can be replaced in less than 1 minute and the inrush current will be no larger than
150% of the rated input steady-state peak value.
When the rectifier is plugged into the system, the system output voltage will not be affected.
2. Active Load Sharing
The rectifier uses advanced digital active load sharing technology that maintains balancing
to within 2A.
3. Output Characteristics
The relationship between output voltage and current is summarized in below table and
depicted graphically in Figure 1-6.
Output Power
Output Current
Output Voltage
4000 W
69 A
58Vdc
4000 W
83.34A
48Vdc

Figure 1-6: Output Characteristics


4. Current Limit Function
The rectifier has current limit function. The current limit point can be set between the ranges
of 6 to 72.9A. The setting is done using the SCU. The current limit accuracy is 2A when the
output voltage ranges from 42 to 58.5 V, and 3A for output voltages ranges from 30 to 42 V,
5A for output voltages below 30V.
5. Adjustable Output Voltage
The output voltage can be set through the SCU within the range of 42 V to 58V. The
accuracy is 0.1V.
6. Fan Control
When the input voltage is within a normal range, the built-in processor adjusts the fans
speed according to the rectifiers internal temperature and Load. For example, a higher
temperature and load will increase the fan speed. Above 45C with full load, the fan will be
operating at full speed. When the input voltage is abnormal, such as very low or high input
voltage, the fan will turn off.
NETSURE 702 IC4 Manual

18

7. Input Over/Under Voltage Protection


The rectifier will shut down and its protection indicator (yellow) will light up when the input
voltage is lower than 85Vac or higher than 300Vac. This condition will be reported to the
SCU and the SCU will process the alarms accordingly.
8. Output over Voltage Protection (HVSD)
There are two kinds of HVSD:
a. The fixed hardware HVSD is 59.5V (within the range of 59 to 60V), In case of hardware
HVSD; the rectifier has to be restarted manually.
b. The software HVSD is settable; its level (from controller) is from 56V to 59V.
The rectifier will shut down when its output voltage is higher than HVSD set point. Note that
the HVSD set point can be modified through the SCU and the permissible range is from 56 V
to 59 V. The occurrence of a HVSD condition will cause the rectifiers alarm indicator (red) to
light up. The failure information will be reported to the SCU and the SCU will process the
failure accordingly. Note also that the rectifier can only be restarted manually should a HVSD
condition occur twice within a 5-minute interval.
The rectifier also has two additional software settings that can be configured using the SCU:
Manual restart and Automatic restart attempt should be within 5 seconds of a HVSD
condition.
9. High Temperature Protection
The rectifier will shut down and its protection indicator (yellow) will light up when its internal
temperature becomes higher than 90C. The causes for the high temperature condition may
be that the ventilation openings are obstructed, the ambient temperature is too high, or the
rectifier fan has failed. The failure information will be reported to the CSU and the CSU will
process the failure accordingly. The high temperature alarm will clear and the rectifier
restored to normal operation when its internal temperature returns to normal values
(hysteresis is between 5 to10C).
10. Communication Failure
The rectifiers protection indicator (yellow) will flash should it experience a communication
failure. The failure information will be reported to the SCU and the SCU will process the
failure accordingly. During a communication failure, in order to protect the battery, the
rectifier output voltage will automatically adjust to 53.5 V (this is a default value which can be
modified using the SCU). The rectifier will revert to normal operation once normal
communication is restored.
11. Fan Fault Protection
An alarm will be generated upon a fan fault. In such cases, the fault indicator (red) on the
rectifier front panel will flash and the rectifier will also inhibit its output. Auto-recovery is
enabled upon the clearing of the corresponding fault.
12. Unbalance of Rectifier Output Current
When the output current of the rectifiers in a DC power system is unbalanced, the rectifier
whose output current is unbalanced will be identified automatically and its protection
indicator (yellow) will light up.
The failure information will be reported to the SCU and the SCU will process the failure
accordingly.

NETSURE 702 IC4 Manual

19

3.1.3 Specifications

1. Environmental

Operating temperature: -40 to 75C


Full rated output power of 4000 W for temperatures -20 to 50C.
Power limitation for temperatures higher than 50C.
Relative humidity: up to 90%
Elevation: 2000 m (power limited for heights above 2000 m)
2. Input

Input voltage: 85 to 300 Vac, single-phase three-wire


Maximum non-destructive input voltage when rectifier is not operating: 415 Vac
Rated input voltage: 195 to 250 Vac
Input current: <22A @ 4000 W, and at an input voltage of 195 Vac
Inrush current: less than150% of the rated input steady-state peak value
Allowable input power frequency: 45-65 Hz

Rated input power frequency: 50/60 Hz


3. Output

Output voltage: 42 to 58 V
Output DC current: 0 to 73 A
Voltage regulation: 1%
Load regulation: 0.5%
Line regulation: 0.1%
Overshoot at startup: 1%
Power factor >0.98 (50% to 100% load)
Efficiency > 95%(50% load at Nominal Voltage)
Ripple 200mV at 0-20MHZ
Acostic Nosie 50db
4. Dimensions

132.5 mm (Height) X 88 mm (Width) X 287 mm (Depth)


5. Weight

Under 3.5 kg

NETSURE 702 IC4 Manual

20

3.2 SCU M523S CONTROLLER


3.1.4 3.2.1 Dimensions and Structure

The appearance of the Controller M523S is shown as Figure 1-1,

LCD
Run indicator

ESC

Functional keys

Alarm indicator
Critical alarm indicator

ENT

Figure 1-1 Appearance of M523S Controller


3.1.5 3.2.2 Main Functions
3.1.6

3.2.2.1 Different Authorities Protected by Different Password Levels

The Controller has 2 passwords of different operation authority: user level password
and engineer level password. The two passwords have the same authority for control
output. But during the setting of system parameters under parameter setting, the
parameters for the setting and the operation functions are different. The engineer
level password will have more operation authorities than the user level password,
including reset system, reset password, change system type.
The passwords and the relevant authorities are listed as follows

Password
Operation authority
level

Default
password

User

123456

Configuration of general parameters

NETSURE 702 IC4 Manual

NetSureTM 702IC4 DC POWER SYSTEM

21

3.3 Operation Panel of the Controller


There are backlit LCD display, functional keypad, indicators and positioning pin on
the front panel of M500S monitoring module, as shown in the following figure:
LCD
Run indicator

ESC

Functional keys

Alarm indicator
Critical alarm indicator

ENT

Figure 2-1 Front Panel of M523S Controller


The description of the LED indicators on the front panel is shown as the following
table.

Indicator

Normal Abnormal
Status
Status

Abnormal cause

Running indicator
(green)

On

Off

The power system has no power supply.

Alarm indicator
(yellow)

Off

On

The power system has an observation


alarm.

Critical alarm
indicator (yellow)

Off

On

The power system has a major alarm or


critical alarm.

The M523S Controller uses a 12864 LCD unit and has 6 functional keys.
The Functions of the 6 functional keys of the Controller are shown in the following
table.
Key

Function

ESC

Return to the upper level menu

ENT

Enter the main menu or confirm the menu operation

and

Shift among parallel menus. For a character string, these 2 keys can be
used to shift among different options

and

Change values at a value setting interface. For a character string, these 2


keys can move the cursor left or right

NetSureTM 702IC4

22

NetSureTM 702IC4 DC POWER SYSTEM

3.1.7 3.3.1 Power-on Sequence

After the system is powered on for the first time, you should set the system type
according to the actual configuration. The monitoring module will restart after the
system type is changed. In that case, you should re-configure those parameters
whose default values are inconsistent with the actual situation. Only after that can the
monitoring module operate normally.
After configuring the system parameters, you can carry out various operations directly
without resetting the parameter values. As for those important parameters related to
battery management, such as BLVD, you should be fully aware of their influence
upon the system before you change their values.
1. The LCD will prompt you to select a language once the monitoring module is
powered on.

English
English

You can use , , or to select the language you want, and press ENT
to confirm.
2. The monitoring module will prompt you to wait, and start initialization.

Waiting

3. The first system information page appears


2004-5-12
53.5V

125A

System:No Alarm
Auto

/BC

The system information is shown in many pages. You can repeatedly press to
view other system information pages in a cycle.

4. At any system information page, press ESC to enter the help page, which
displays software version (SW), product code (PC), product reversion (PR) and serial
number (SS).

NETSURE 702 IC4 Manual

NetSureTM 702IC4 DC POWER SYSTEM

23

SW: V1.20
PC: 1M502D
PR: A00
SS: 01051200012

5. At any system information page, press ENT to enter the MAIN MENU page,
which contains 3 sub-menus: Status, Maintenance and Settings.
MAINMENU
Status
Settings
Maintenance

Energy Saving
Fast settings

You can press or repeatedly to select a sub-menu, and press ENT


to enter the sub-menu. Press ESC to return to the menu of higher level.
1) Status
Including rectifier information, active alarm information and alarm history information.
2) Maintenance
The maintenance operation can be conducted only when the battery management
mode is set to Manual. The maintenance includes battery FC, BC and test, load
power off/on, battery power off/on and rectifier voltage trimming, current limit, switch
control and resetting.
3) Settings
Includes the setting of alarm parameter, battery parameter, AC/DC parameter, rectifier
parameter, system parameter and communication settings.
4) Energy Saving
Includes the setting of cyc period, rectifier work and rectifier limit when the save
option is enabled.
5) Fast Settings
At the Fast Settings page, you can set the system type and battery capacity

NetSureTM 702IC4

24

NetSureTM 702IC4 DC POWER SYSTEM

The detail information on menu is as follows:


The root screen displays the system voltage, load current, alarm status and
system mode of operation. Press or to view other rectifier
Display

information.
The other information consist of battery voltage, battery capacity, battery
current, save status, rectifier o/p power, batt. Cyc boost charge after, AC
voltage, percentage load, battery temperature & ambient temperature.

Main Menu Press ENT to go to main Menu


Status

Displays the rectifier information, active alarm information and alarm history
information
Rectifier information like serial number of the rectifier, the output voltage, output
current, the AC/DC switch status, the AC input voltage. Current limiting

Rectifier

threshold, the AC-limited power status, the temperature-limited power status.


Press or to view other rectifier information.
Press ENT, use the or key to select the active alarm and press the
ENT screen to confirm and run the active alarm information screen.

If there is no alarm, the screen will display no active alarm.


If there is active alarm, the screen will display the following information:
Active Alarm

The alarm sequence number, the alarm level, the alarm name and the alarm time
(including the year, month, day, hour, minute, and second).

The display sequence will follow the sequence of the occurring time of the
alarms. The latest alarm will be displayed as the first one. The user can use the
or key to view all the active alarm information.

NETSURE 702 IC4 Manual

NetSureTM 702IC4 DC POWER SYSTEM

25

Press ENT, use the or key to select the alarm history and press the ENT
screen to confirm and run the alarm history information screen.

If there is no alarm history, the system cannot enter the lower level menu.
Alarm History

Up to 200 pieces of alarm records can be stored. If there are more than 200 pieces of
records, the earliest records will be cleared automatically.

On the Controller, only the following information about the alarm history will be
displayed: alarm sequence number, alarm name, alarm occurrence and ending time
(including year, month, day, hour, minute and second).
When the system battery management adopts the auto mode, no control output operation
can be conducted.
When the system battery management adopts the manual mode, the user can conduct
control output operation, including battery boost charge, float charge and test, LLVD
power on/off, BLVD power on/off and rectifier voltage adjustment, current limiting and
DC on/off, AC on/off and reset control.
Press the ENT key to select the Maintenance menu.
When the battery management is set as manual, the user can manually control the
Maintenance

battery under the system control output menu. If the system battery management is in
auto state, the user cannot enter into the system control output menu.

Press the ENT key, input the correct operation password on the pop up display screen,

Press ENT key again, and then the user can enter into the control output menu.
When inputting the password, user or key to modify the number and
Or to shift left or right. After the modification, press ENT key to confirm.

Includes the setting of the alarm, battery, AC/DC, rectifier, system and communication
parameter.
Press ENT, Use the or key to select the parameter setting and press ENT
Settings

to confirm. The system prompts to enter password.


Press the or key to input the correct password number for each digit, press the
ENT key to confirm and enter into the parameter setting submenu screen.

NetSureTM 702IC4

NetSureTM 702IC4 DC POWER SYSTEM

26

ALARM SETTINGS
No.
1

Alarm

Description

Alarm level

SPD Fault

SPD failure

Major

Related
relay
None

Related parameter
-

None

Defined the alarm name by


user, at most 10 letters. In this
system, eight DIs can be
defined. Among which, the
first DI is defined as SPD
Fault, the remained seven DI
can be defined freely

DI

No alarm

None

AC
High

Voltage

AC input voltage higher than


the setting of AC input overvoltage alarm point

Major

Over- voltage alarm


None

AC
Low

Voltage

AC input voltage lower than


the setting of AC input
under- voltage alarm point

Major

Low- voltage alarm


1

Mains Failure

All the AC input voltages


from the rectifier are less than
80V

Critical

DC Volt High

DC output voltage higher


than the setting of DC output
over- voltage alarm point

Major

Over- voltage alarm


2

DC Volt Low

DC output voltage lower than


the setting of DC output lowvoltage alarm point

Major

Low- voltage alarm


None

DC Volt Under

DC output voltage lower than


the setting of DC output
under- voltage alarm point

Batt Over Temp

Battery temperature higher


than the setting of Temp

10

Batt Temp High


Alarm

Battery temperature higher


than the setting of Temp

11

Batt Temp Low


Alarm

Battery temperature lower


than the setting of Temp

12

Ambient Temp
High Alarm

Ambient temperature higher


than the setting of Temp

13

Ambient Temp
Low Alarm

Ambient temperature lower


than the setting of Temp

T1 No Probe

Configured with temperature


sensor 1 but not connected

Underalarm

No alarm

voltage

None
Over Temp alarm
point

Critical
None

High Temp alarm


point

Observation
None

Low Temp alarm


point

Observation
None

High Temp alarm


point

Observation
None

14

Low Temp alarm


point

Observation
None
Major

NETSURE 702 IC4 Manual

NetSureTM 702IC4 DC POWER SYSTEM

27

None
15

16

17

T2 No Probe

Sensor 1 Fault

Sensor 2 Fault

Configured with temperature


sensor 2 but not connected
Temperature
measures
temperature

Major

None

sensor
1
unreasonable
Major

Temperature
measures
temperature

None

sensor
2
unreasonable
Major

5
18
19

20

LVD 1

Load low voltage disconnects


Battery
low
disconnects

LVD 2

Load
Fuse
Alarm 1 ~ 9

Major

LLVD enabled
4

voltage

Load failure caused by


overload,
short
circuit,
manual disconnect, and alarm
circuit failure

Major

BLVD enabled
None

Major

None

21

22

23

24

25

Aux Load Fails

The last load fuse failure

Major

Batt Fuse Alarm

Battery failure caused by


overload,
short
circuit,
manual disconnect, and alarm
circuit failure

Major

None

Batt
High

Charging current of battery


string 1 higher than the
setting of Over (Charging
over current limit)

Observation

None

Over (over current


point)

Charging current of battery


string 2 higher than the
setting of Over (Charging
over current limit)

Observation

None

Over (over current


point)

Batt
High

Curr

Curr

Rect AC Fail

AC input voltage of this


rectifier lower than lowvoltage alarm point

3
Critical

26

Rect Over Temp

The internal temperature of


the rectifier is higher than 90

Observation

27

Rect Failure

The rectifier voltage is higher


than upper limit voltage

Major

28

Rect Protect

Rectifier
performs
selfprotection and has no output

Observation

29
30

Rect Fan Fails


Rect Derated

Rectifier fan fails


Rectifier limits its output
power

Critical

Observation

NetSureTM 702IC4

28

31
32

NetSureTM 702IC4 DC POWER SYSTEM

Rect
Respond

Not

Rectifier
does
communicate
with
monitoring module

not
the
Critical

Rectifier shut down under


high voltage

HVSD

None

33

Multi-Rect
Alarm

More than
alarm

two

rectifiers
Major

None

34
35
36

Self-detect Err
Manual Mode
Non Float Status

Hardware Self-detect Error


Battery management is in
manual control mode
Battery is not under float
status

No alarm

None

No alarm

None

No alarm

None

37

38
39

40

Batt Discharge

Load
Alarm

share

Batt Test Fail

Short Test Fail

Battery is discharging

No alarm

In the system with load


current shunt, the sampled
load current plus battery
current differs greatly from
rectifier current
Battery discharging
shorter than expected

No alarm

None

time

In
short
test,
battery
discharging capacity is bigger
than setting value

Observation

None

Observation

None

41

Volt
Discrepancy

Actual output voltage is


different from both the
measured DC bus voltage and
different from the voltage
reported by the rectifier to
monitoring module. The error
is bigger than 1V

Observation

None

42

Maintain Alarm

Time to maintain system

Observation

None

43

Rectifier Lost

The monitoring module has


detected a reduction in the
number of running rectifiers

Major

None

44

Save Power

The system is running under


energy saving status

No alarm

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29

Alarm Mode
Parameter
Name

Setting Range

Default Value
Alarms
different

Alarm Type

44 names of alarm

have

events

levels
different

Value Description
of

types
different
and
Relate

Select

those

alarm

events

Alarm Type

whose levels and relate relays


should be reset

Relays
There
Level

Critical,

Major,

are

audible/visual

Observation, None

different
alarm

modes

and callback modes for alarm


events of different levels

Level

Empty: The corresponding


dry contact will not output
alarm information upon an
alarm event
Related Relay

Empty, No.1 ~ 6

No. 1 ~ 6: There will be a


dry contact in the range of

Related

No.1 ~ 6 that outputs the alarm

Relay

information upon an alarm


event
The
DI No.

No. 1 ~ 8

corresponding

connecting terminals, queued

up in the order that the


hardware switches are put

DI No.

High: alarm upon high level;


Alarm Mode

High, Low

Low

Low: alarm upon low level.

Alarm

Set according to the actual

Mode

situation
When there are DI alarms, this
DI Name

Figures or letters,
10 at most

SPD

parameter shows the alarm


name
defined.

NetSureTM 702IC4

you

have

actually

DI Name

30

NetSureTM 702IC4 DC POWER SYSTEM

Alarm Control
Parameter Name

Setting Range
open,

off,

minutes,

Voice sign

Default Value

Value Description

Normally on

Launch alarm beeping duration control

3
10

minutes, 1 hour, 4
hours

Clear

alarm

history

Yes, No

No

Setting Range

Default Value

When the value yes is selected, clear the


alarm history information

Battery Settings
Parameter Name

Value Description
In the Auto mode, you can manage the
system through the monitoring module.
In the Manual mode, you can manage the

Mgmt Mode
(Management

Auto, Manual

Auto

mode)

system manually, as well as calculate battery


BC

time

automatically.
under-voltage

protection
Upon

and
the

alarm,

capacity

system
system

DC
can

automatically switch to the Auto mode

Batt

You should set this parameter according to

String

(number of battery

0~4

strings)

the actual battery configuration. If Batt


Shunt is set as Y, there should be
batteries actually configured

Rated AH (rated
capacity)

The capacity of a single battery string. You


50 ~ 5000Ah

600Ah

should set this parameter according to the


actual battery configuration

Batt Shunt1

Yes, No

Yes

Batt Shunt2

Yes, No

No

1-5000A

500A

1-500mV

75mV

You can set the shunt parameters when the


Shunt

co-eff

current
Shunt co-eff Volt

system type is SET.

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31

LVD
Parameter
Name
LVD1 Enable

Setting Range

Default Value

Value Description

Y, Y

Select Y to enable LLVD function

Select Y to disable the BLVD function

LVD2 Enable

If selecting the According to voltage, then the


LVD contactor shall operate according to the
LVD1 Volt

40V ~ 60V

voltage

44.0V

If selecting the According to time, then the


LVD contactor shall operate according to time.

LVD2 Volt

43.2V

Charge
Parameter Name

Setting Range

Default
Value

Value Description
In

Float

42V ~ 58V

54.0V

the

FC

state,

all

rectifiers output voltage

The Boost must be

according

higher than the Float

to

the

set

state,

all

Float
In
Boost

55.2V

the

BC

rectifiers output voltage


according

to

the

set

Boost
When the monitoring module detects that the battery
charging current is higher than the Limit, it will
control the current of the rectifiers, through which it
Limit

(current

limit)

0.1 ~ 0.25C10

0.1C10

can limit the battery charging current.


C10 is the battery rated capacity, generally set to 10
~ 20% of the rated capacity of one battery string

Over (over current


point)

When the monitoring module detects that the battery


0.3C10 ~ 1.0C10

0.3C10

charging current is higher than the Over, it will


raise the battery charge over-current alarm

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NetSureTM 702IC4 DC POWER SYSTEM

32

Automatic Boost

Y, N

Enable

Select Y to enable this function


Select N to disable this function
The monitoring module will control the system enter
the BC state when the battery capacity decreases to

Automatic Boost

0.050C10

Current

0.080C10

0.06C10

the value of To Boost Capacity, or when the charge


current reaches the To Boost Current. The charge
voltage will be the Boost

Automatic Boost
Cap

10% ~ 99%

80%
The system in the BC state will enter the FC state

Const

Boost

Current

0.002C10

0.01C10

0.02C10

when the charge current decreases to the Constant


BC Curr and after the Duration. The battery charge
voltage then will be the Float

Const Boost Time


Cyclic

Boost

Enable

30min

180min

1440min
Y, N

Select Y to enable this function


Select N to disable this function
Select Y, and the monitoring module will control

Cyclic

Boost

Period

the system to enter the Cyclic Boost when the FC


48h ~ 8760h

2400h

time reaches the Cyclic Boost Interval. The battery


charging voltage is the preset Boost, and the time is
the preset Cyclic Boost Time

Cyclic

Boost

Time

30min

720min

2880min

To ensure safety, the monitoring module will


forcefully control the system to enter the FC state if
Boost Limit Time

60min

1080min

2880min

during the BC state, the BC time reaches the Boost


Limit, or abnormalities occur (such as AC failure,
battery route faulty, and rectifier communication
failure)

Battery Test Parameters


Parameter

End Test Volt

End Test Time

Factory

Range
43.1V

setting
~

57.9V
5min
1440min

45.2V

300min

Value description
The monitoring module will stop the test and change to FC
if the battery voltage reaches the Battery Test Voltage, or
the discharge time reaches Battery Test Time, or the battery
capacity reaches Test End Cap

NETSURE 702 IC4 Manual

NetSureTM 702IC4 DC POWER SYSTEM

0.01C10

End Test Cap

0.95C10

Cyc Test En

Y, N

33

0.7C10
Select Y to enable this function

Select N to disable this function

01-01-00:00
day, 04-01-00:00

Month,

Cyc Test Time

time

07-01-00:00

When the parameter Cyc Test En is set to Y, the monitoring


module will test the battery according to the 4 sets of test
time

10-01-00:00
Short Test Enable Y, N

Whether using Short Test function

Short Test Alarm 1A ~ 100A

10A

If the battery is not discharged within the ShortTest Cycle,

Short Test Period 24h ~ 8760h

720h

the monitoring module will start a short test, whose


operation time is set by the parameter ShortTest Duration.
By the end of the test, if the difference in the discharge
currents of batteries is bigger than the Alarm Current, the

Short Test Time

1min ~ 60min 5min

battery discharge imbalance alarm will be raised. This


alarm will automatically end after 5min of delay. Also you
can end it by confirming it

Stable

Test

Enable
Stable

Test

Current

Y, N

The stable test is conducted with constant battery current,

whose value is set through the parameter StableTest


Current. If the parameter StableTest Enable is set to Y, and

0 ~ 9999A

the test will be started once the battery satisfies the test

9999A

condition

Temperature Compensation Co-efficient parameters


Parameter

Range

Center

10C

Temp

40C

Factory setting

Value description

25C

FC = BattTemp Center Temp) * Temp Coeff

72mV/C/str
Coeff

~ system)

500mV/C

36mV/C/str
system)

Temp1

Temp2

(48V

(24V

Upon alarms such as Rect Not Respond, DC Volt


High, DC Volt Low and Batt Fuse Alarm, the
monitoring

will

not

do

temperature

compensation to the battery FC voltage

Ambient

Ambient Temp refer to the measurement of the

Temp,

ambient temperature sensor at the local power system.

None,

None

Battery Temp refer to the measurement of the battery

Battery

temperature sensor at the local power system.

Temp

None means there is no measurement input


When

Batt T H2

module

-40C
100C

50C

the

detected

battery The Batt T H1

temperature is higher than Batt T H2, must not

be

the monitoring module will raise an higher than the


alarm

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Batt T H2

NetSureTM 702IC4 DC POWER SYSTEM

34

When
Batt T H1

-40C

detected

battery

temperature is higher than Batt T H1,

50C

100C

the

the monitoring module will raise an


alarm

Batt T L1

-40C

The monitoring module will raise an alarm when the

0C

100C

detected battery temperature is lower than Batt T L1

AC Settings
Factory

Parameter

Range

Over Volt

50V ~ 300V

setting
280V

Value description
The monitoring module will raise an alarm when the AC input
voltage is higher than the Over Volt
The monitoring module will raise an alarm when the AC input

Low Volt

50V ~ 300V 180V

voltage is lower than the Low Volt. The value of the Low Volt
must lower than that of the Over Volt

Under Volt
AC In

AC PH

50V ~ 300V 80V

Setting according to actual requirement

Auto,

Setting according to the AC input mode of AC sampling board.

No,

Manual
1-PH, 3-PH

No

3-PH

Choose No if the AC sampling board is not configured


Setting according to the actual configuration. Choose 1-PH and
3-PH if the AC sampling board is configured

DC Settings
Parameter

Factory

Range

setting

Value description
The DC Over Voltage alarm will be raised when the

Over Volt

58.5V

system DC output voltage is higher than the value of The values of


Over Volt

these

three

The DC low voltage alarm will be raised when the parameters


Low Volt 1

40V ~ 60V 45.0V

system DC output voltage is lower than the value of should


Low Volt 1

be:

Over Volt >

The DC under voltage alarm will be raised when the Low Volt 1 >
Low Volt 2

45.0V

system DC output voltage is lower than the value of Low Volt 2


Low Volt 2

L-Shunt

Y, N

Shunt Coeff

1A

Current

5000A

Shunt Coeff

1mV

Volt

500mV

N
~

500A

75mV

Setting according to the actual instance

They can be reset when the shunt options are SET in the system
with load shunt-

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NetSureTM 702IC4 DC POWER SYSTEM

35

Rectifier Parameters
Parameter

Range

Factory
setting

Value description
Y: The monitoring module will prompt you to set rectifier position

Position En

Y, N

before the rectifier and monitoring module are powered on.


N: You need not to set rectifier position
R-Posi: represented in two figures, the first figure represents the rectifier
number, the next figure reprents position number. Press ENT to select the

R-Posi

1 ~ 30

rectifier, press or to change position number. When the monitoring


module communicates with the rectifier, the green indicator on the
corresponding rectifier will blink
The rectifier over voltage alarm will be raised when the rectifier output

HVSD

56V ~ 59V 59V

Default V

48V ~ 58V 53.5V

Walk-in On

Y, N

The output soft start function means the rectifier voltage will rise from

Walk-in

8s ~ 128s

8s

0V to the Default Volt after the Walk-in time

Interval T

0s ~ 10s

0s

voltage is higher than the HVSD voltage


Default output voltage when communication interrupted. Must be lower
than the HVSD voltage

The monitoring module can set the DCDC Interval Start of the modules.
Start time = module address * interval time
The monitoring module can set the rectifier to OverVolt Enable,

AC
On

OverV

meanwhile, the rectifier can start forcibly. The monitoring module will
Y, N

set automatically the rectifier with least address to have this function. If
the rectifier always exceeds the normal voltage for 60s, the function will
be canceled automatically

ACCurrLim 1A ~ 50A

30A

The monitoring module limits the input current of the rectifier in the AC
current limiting.

NetSureTM 702IC4

36

NetSureTM 702IC4 DC POWER SYSTEM

System Setting Parameter


Parameter

Range

Factory
setting

Value description

Lang

Chinese,
English

Chinese

Set according to your need

Tzone

Set according to actual instance

Date

2000
2099

Set the time according to the current actual time, regardless of


whether it is a leap year or not

System Type

24V/100
24V/300
24V/500
24V/1000
24V/SET
48V/100
48V/300
48V/500
48V/1000
48V/SET

48V/500

The system type of the monitoring module has been set according
to the actual instance before the monitoring module is delivered
with power supply system. You need not to change the value except
that the monitoring module is replaced with a new one.
After changing the type, the monitoring module will restart and the
other parameters will resume the default. You need to reset and
change some parameters according to the battery and equipment
configured with system

ComDownLoad

Y, N

Reset PWD

Y, N

Whether resetting the password to the default

Reset Para

Whether resetting the parameters to the defaults

Op1 PWD

Op2 PWD

Adm PWD

The password can be 6 digits long at most. If it is shorter than 6


digits, end it with a #. Use or to change the number, and or
to move the cursor left or right. Press ENT to confirm. You
should input the same number twice to complete the setting

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37

Communication Parameter
Parameter

Range

Factory setting

Address

1 ~ 254

Comm Mode

MODEM

RS232

1200bps

BaudRate

9600bps

9600bps

IP/Subnet/Gate

CallbackTime

Phone Number

Value description
The addresses of power systems that are at the same
monitored office should be different
The system only supports RS232 mode communication
Make sure the baud rates of both the sending and
receiving parties are the same

Set according to actual instance

The SCU will generate rectifier lost alarm incase SCU misses out any rectifier during CAN
initialization. The alarm can be reseted as follows

Prompt:

The Rectifier Lost alarm can be cleared: on the alarm screen, press right key, then press ENT twice
after

a prompt to clear off the rectifier lost alarm is displayed on the screen. The SYSTEM

MAINT alarm can be cleared off in the similar way.

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38

NetSureTM 702IC4 DC POWER SYSTEM

Chapter 4 Installation & Commissioning Procedure


4.1 Pre-Checks for Installation
Make sure that proper tool kit and Spares kit are been carried for usage at Installation site
Ensure the readiness of the foundation.
Ensure availability of complete system layout drawing
Check for availability and proper routing of power cable from Utility Distribution box to
Unit.
Check for cable connectivity from unit to battery bank
Ensure for healthy earthing (Ground) connection and also for the connection of lightening
arrestor on tower (Lightening arrestor can be verified from Site owner)
Ensure there in no damage to packaging while transportation

4.2 Accessories
Mechanical tool Kit (Spanner Set, Screw driver set, cutter, pliers & crimping tool)
Multi meter, Clamp (AC/ DC) meter with probes
Wires & wiring accessories PFC alarm connection.

4.3 Installation procedure


Receipt of Material and its inspection for ensuring no damage while transportation is to
observed and recorded.
Record the Unit SL No/ Box No and open the packaging. Ensure that there is no physical
damage to the unit.
Check for the components, boards, connectors and contactors physical condition and their
intactness with corresponding placement position.
Ensure that all connectors and wiring is tightly connected.
Ensure that the panel has a instruction manual and panel wiring diagram within it. Read
the instruction manual for special instructions if any.
On completion of visual inspection, start with the mounting arrangements. Lift the panel
and place it at predetermined position.
Place the unit properly on drill holes and mount rigidly using standard fasteners.

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39

4.4 Wiring up the interconnection between Unit, Mains & Battery

DCPS is dispatched from the factory with complete internal wiring as one unit. Alarm
connections from PFC card to BTS are required to be carried out.
Power connections between DCPS to Battery Fuse and DC Load; DCPS to utility mains
are to be carried out.
Ensure the polarity of phase and neutral while making Mains connections to Input MCB.
Ensure while connecting Battery, Battery fuse is removed.
After connecting Battery check the polarity, If it reverse BLVD operated.
Correct the battery Polarity. Then & then only switched on mains & put battery fuse.
Also ensure the R, Y, B and N polarities while making connections.
Ensure the earthing Cable is connected to Earth Bus-bar

4.5 General Functional Procedure

Check for all connections and wiring as per connection chart.


Check for tightness of connections especially at MCBS and contactors.
Check whether all the MCBs are in off position.

Ensure proper connections (Polarity) of Battery bank

NetSureTM 702IC4

40

NetSureTM 702IC4 DC POWER SYSTEM

Chapter 5 Testing Procedure


Long-distance transportation may cause damage to the cabinet, rectifiers and monitoring
module, furthermore, assembly and connection errors may occur during the assembling of
the power supply system. Therefore, to avoid accidents, testing must be conducted strictly in
accordance with the testing procedures after the system is assembled instead of hastily
putting the system into operation.
Close attention should be paid to the following safety points during testing.

Before switching on the system, check if the connections and screws inside the cabinet
are loose.
The technical contents contained in testing are extensive; therefore the testing engineer
must have had relevant technical training.
The testing involves working with live wires. Please stand on a dry and insulated object
during operation. Do not wear watch, necklace or any other metal things. Use insulated
tools during testing.
Avoid touching two live objects with different potentials.
During testing, do check if the conditions of the relevant parts are normal before the
switch-on operation.
During operation, if operation by other people is not permitted, a prohibition sign "No
switch-on, in operation" should be hung on the distribution equipment.
Close observation is required during the testing. The system should be turned off
immediately if any malfunction occurs. The cause of the malfunction must be found out
before resuming the testing.

5.1 Testing procedures


1. Resetting system
2. Testing AC distribution
3. Testing rectifier
4. Testing monitoring module
5. Testing distribution switches
6. Battery connection
7. Load connection
8. Setting system parameters

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41

5.2 Resetting System


To prevent improper transportation or installation error from damaging the system, before
powering on the system and putting it in operation, first you must disconnect some branches
of the system, and connect them one by one during testing.
1. Switch off all of the distribution switches of the AC/DC distribution units.
2. Make sure that the battery fuse or the shorting stub of the battery is disconnected.
3. Make sure that the load MCB is pulled switched off.

5.3 Testing AC Distribution


1. Turn on the AC distribution switch in the power room to feed the mains supply to the
power supply system; then measure the L-N voltage of the three phases with a multi-meter
to confirm the mains condition. If everything is normal, proceed with the next step.
2. Turn on the corresponding AC input MCB.

5.4 Testing Rectifier


1. Turn on one rectifier input MCB in the AC distribution unit to feed AC supply to the
corresponding rectifier, the rectifier should operate normally.
2. Turn off this MCB, and turn on the other rectifier input MCBs one by one to check if all the
other rectifiers operate normally.
If all of the rectifiers can operate normally, switch them on. In case of rectifier malfunction,
take the rectifier out and inspect it.

5.5 Testing Monitoring Module


When the rectifiers are operating normally, switch on the monitoring module, the monitoring
module should start and display the start screen. If the system self-test is normal, seconds
later, the following main screen will appear.
There are default system parameter settings in the monitoring module, including the AC
voltage alarm points, DC voltage alarm points, battery management parameters, which are
available on the parameter card delivered with the system. If the battery capacity or charging
parameters set by user are different from those on the parameter card, or if user has
different BLVD and LLVD management requirements, please reset the system parameters
according to the actual situation, and record the new settings on the parameter card.

5.6 Testing Distribution Switches


1. close/disconnect the AC input MCBs, the rectifiers should operate normally.
2. Respectively operate the buzzer switch.
3. Close the AC output MCB for user equipment; mains supply should be fed to the
corresponding user equipment.

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42

NetSureTM 702IC4 DC POWER SYSTEM

5.7 Battery Connection

Danger
A. Before turning on the battery switch, confirm with a multi-meter that the battery is not
connected with reverse polarity.

B. When connecting the battery, be careful not to short the two battery terminals.
C. When connecting two batteries, be careful to avoid battery mutual charging due to
unequal terminal voltages of the two batteries.
1. Turn on one rectifier, and set the rectifier float voltage to a value with less than 0.5 V
difference from the battery voltage through the monitoring module
2. Close the battery fuse or the shorting strip of the battery that are disconnected during
installation to connect the battery branch to the power supply system, the BLVD contactor
should be able to close normally to parallel connect the battery to the rectifier output;
3. Readjust the rectifier float voltage to the standard value 52V through the monitoring
module (at this time, the rectifier charges the battery, and may enter current limiting state, so
the actual output voltage cannot reach the standard value, note that adjustment should be
done after all rectifiers are started)
4. Switch on all of the rectifiers one by one
5. Measure the system DC output voltage with multi-meter to check if it is normal or check if
the system works normally through the monitoring module.

5.8 Load Connection

Danger
Before connecting load to the system, check with a multi-meter if the connection polarity of
the load and the power system is correct and the voltage is normal.
1. Close the load MCB, or insert the load fuse with special handle, DC power should be fed
to the load;
2. Adjust the system parameters through the monitoring module, and make sure that the
information viewing and output control functions are normal.

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43

Chapter 6 System Specifications & General Requirements


6.1 Technical Specifications
Input
Operating Voltage
Power Consumption
THD
Power Factor
Output
Output Voltage
Output Power
O/P Current

Recommended Range
156V to 502V for three phase
12.9 KW
< 5%
> 0.99
Recommended Range
42V to 58V by rectifier,
12.0 KW
250A @ 48V Constant Power,

Efficiency
Ripple

>93.5%
<100mV p-p

Environmental Conditions
Ambient temperature
Humidity
Dust
Sunlight
Corrosives
Shake
Insects, pests, and
termites
Mildew
Moisture

Recommended Range
-5~45C
90%RH, non-condensing
3
1mg/m
No direct sunlight
No pollutants, such as salt, acid, and smoke, etc.
2
1.5m/s

Fire protection
Component

No flammable on the top/bottom of the cabient.


Dimensions

Weight

Monitoring module

1U(H) 2U(W)

0.15 kg

Rectifier

124.3 mm(H) 84 mm(W) 287 mm(D)

3.5 kg

None
None
Water proof

6.2 Guideline for Earthing


Equi-potential earthing should be provided, refer table 5-2 for earthing resistance.
Table 5-2 Requirements on earth resistance of communication station
Earth
resistance
<1
<3
<5
<10

Applications range
Comprehensive building, international telecom bureau, tandem office, SPC switching office
above 10000 lines, toll office above 2000 routes
SPC switching office above 2000 lines and below 10000 lines, toll office below 2000 lines
SPC switching office below 2000 lines, opto-terminal station, microwave tandem station, mobile
station.
Microwave relay, optical cable relay, small size earth station.

The protective earth of mains input should be directly connected to the user earth bar in the
power room.

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44

6.3 System Input And Output Recomanded Connections


Connection
AC Power
distribution
DC Power
distribution

Earth

L&N

Specs
4 core 6 sq mm for 3 phase Copper Flexible Cable with Pin type Lugs

AC Earth PE

Single Core 50sq mm Copper Flexible Cable

+ve busbar

Connection with RING Type Lugs with holes suitable for M6 or M8 hardware

Load ve

Suitably rated cable with Pin type lugs for MCB and Ring type lugs for Fuses

Battery ve

Max 50 sq mm single core copper flexible cable with RING type lug

Telecom
Ground

Single Core 50 sq mm Copper Flexible Cable with RING type lug suitable for M8
or M6 hardware

6.4 Recommanded Torque


The torque mentioned below is applicable only for sheet metal or bus-bar tightening.
Torque Settings for Hardware Metric
Screw Size
Torque
Torque
Screw Size
Torque
Torque
(Nm)
(inlbs)
(Nm)
(inlbs)
M2
0.24
2
M5
4
35
M2.5
0.48
4
M6
7
62
M3
0.9
8
M8
18
145
M3.5
1.4
12
M10
34
300
M4
2
18
M12
58
513

6.5 List of Recommanded Spares


SR.NO.

Item Description

ENPI Ordering Code

1.

Rectifier Module R48-4000W

273902130706

2.
3.

Controller SCU M523S


Temp Sensor

000003034706
278292000000

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45

Chapter 7 Installation Preparation


This chapter introduces installation requirements, storage conditions, installation preparation
and unpacking inspection.

7.1 Installation Requirements


Environmental Requirements: The environmental conditions listed in Table 5-1 must be met
when locating the equipment.
Table 5-1 (Environmental conditions for the equipment room)
Environmental conditions

Recommended range

Ambient temperature

-10C j; to 55C (de-rating from 40C)

Humidity

90%RH, no condensation

Dust density

1mg/m3

Sunlight

No direct sunlight

Corrosive materials

No pollutants, such as salt, corrosive materials, and


smoke

Vibration

1.5m/s

Harmful organisms

None

Mould

None

Dampness

The shelter should be waterproof

The equipment may be prematurely damaged if dust or sand accumulates in it. The following
measures are recommended for dirty environment:
1. The equipment should be installed in an airtight and air-conditioned room. The air
conditioner filter should be adequately maintained without being obstructed. To reduce the
dust in the equipment room, unattended equipment room is recommended.
2. Clean the air filter periodically to provide clean air.

7.2 Layout Requirements Of The Equipment Room


Antistatic
As for antistatic requirement, the absolute value of the static voltage of the equipment, wall
and people to the ground should be less than 200V. Raised floor or antistatic ceramic tile is
highly recommended for the equipment room. The antistatic earth resistance should be no
greater than 10. Care should be taken regarding antistatic during equipment unpacking,
transportation and operation.
Weight capacity and shockproof
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NetSureTM 702IC4 DC POWER SYSTEM

When installing the power system in areas subject to frequent earthquakes, shockproof
measures should be taken. Firstly, expansive bolts should be used to fix the system;
secondly, the system should be reinforced as shown in Figure 1-20 to enhance its
shockproof ability. Because the power supply system is relatively heavy, the weight capacity
of the equipment room should meet relative requirements and is determined based on the
equipment configuration.

Figure 1-20

Rein forcing the cabinet for shockproof purpose

Fire protection facility


The equipment room should comply with relevant fire protection regulations and
requirements for power distribution, and provide adequate fire protection facility, such as
dry-chemical extinguisher and automatically explosive fire protection ball.

7.3 Power Supply


General
Mains power should be used as the main AC source; backup batteries and generator should
be provided according to the actual power source conditions. AC source composed of mains
power and user-provided generator should use centralized power supply mode to supply
power, and low voltage AC power supply system should use three-phase five-line (the
neutral line is invalid) mode.
The AC power cables should be copper core cable and sized to suit for the load. It is
recommended that the power cables outside the equipment room should be buried directly
under the ground or by means of cable pipe. Power cables should be laid separately from
signal cables.

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47

7.4 Safety Protection


Lightning protection & surge protection
The lightning protection and earthing system of telecom stations should comply with relevant
standards.
The power supply system has Class-C SPD. The preceding AC input equipment should be
equipped with a Class-B SPD. To achieve better surge protection, it is recommended to
mount Class-B SPD before the AC mains is connected to the system. The mounting of
Class-B SPD is shown in Fig 1-20.
Class-B should be purchased and mounted by the user. If condition permits, it is
recommended that the cable length between the Class-B SPD and the AC distribution unit of
the power supply system range between 5 ~ 10m. And this section of cable should be routed
indoors to avoid direct lightning strike. When mounting the Class-B SPD, attention should be
paid to the sectional area and length of the cable connecting the Class-B SPD: the sectional
area should be no less than 25mm2, the cable should be as short as possible, and so is the
earth cable of the Class-B SPD. The SPDs should be inspected periodically to ensure their
normal operation.
Powersupply
system
5~10m
A
B
C
N
PE

System earth bar


Class-B
SPD

Class-C
SPD
SPD
earth

48VDC
DC earth

SPD
earth
DC earth cable
Protective earth

Protective earth cable

User earth bar

Figure 1-20 Diagram of SPD mounting & system earthing

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7.5 Equipment Running Environment Checklist


The equipment running environment checklist is given in Table 5-3.
Table 5-3

(Equipment running environment checklist)

No.

Item

Index

Pass

Ambient temperature in equipment room

-10C to +55C

Yes/No

Humidity in equipment room

95%

Yes/No

3
4
5

Lighting in equipment room


Height of equipment room
Static electricity in equipment room

Yes/No
Yes/No
Yes/No

Weight capacity and quakeproof ability

70 to 200Lux
3m
Lay antistatic floor or antistatic rubber
Accord with Level 8 quakeproof, and safety must be
ensured

Radiation

No blockage in equipment radiation passage

Yes/No

Damp proof

No mildew breeding conditions

Yes/No

Dust-proof

No conductive dust and gas which deteriorate insulation

Yes/No

10

Fire protection

Fire fighting equipment such as fire extinguisher

Yes/No

11

Earth resistance

In accordance with relevant standards

Yes/No

Yes/No

12

Sectional area of SPD earth cable

Not less than 25mm the shorter the better

Yes/No

13

Colour of protective earth cable

Greenyellow

Yes/No

14

Earth connection

Via suitable Copper Cable

Yes/No

15

Tablet, symbol, tag of customer equipment

Complete and clear

Yes/No

16

Violent vibration and shock

None

Yes/No

17

Sectional area of AC distribution cables

According to design specifications

Yes/No

18

Fluctuation range of AC input voltage

According to equipment input specifications

Yes/No

19

Frequency fluctuation range

45Hz to 65Hz

Yes/No

20

Voltage of neutral line to ground

Less than 10V

Yes/No

21

Power of backup power source

Twice the actual capacity

Yes/No

22

Pollution or interference in power network

None

Yes/No

23

Should be marked with identifier

Yes/No

24

Colour code of AC bus


Capacity of the customer AC distribution
cabinet

Meet equipment requirements

Yes/No

25

Wiring of AC distribution cables

According to standard specifications

Yes/No

26

Colour code of DC load cables

According to standard specifications

Yes/No

27

Sectional area of DC distribution cables

According to requirements

Yes/No

28

Earth wiring

According to specifications

Yes/No

7.6 Storage Conditions


The product should be kept in the packing box prior to use. The warehouse ambient
temperature should range between -40C and 70C, and the relative humidity should not be
higher than 95%. Toxic gas, flammables, explosives, corrosives, severe vibration, shock and
strong magnetic field are not permitted in the warehouse.

7.7 Component Replacement Process


1. Switch OFF the system.
2. Remove the faulty component (PCB, SPD, Rectifier Module etc.) by removing connectors.
3. Replace faulty components with new one. Place all the connectors to its original position.

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4. Check the tightness & switch on the system again and check its function.

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NetSureTM 702IC4 DC POWER SYSTEM

Chapter 8 Electrical Schematic

Fig. 8.1 Power Circuit Diagram

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NetSureTM 702IC4 DC POWER SYSTEM

Fig. 8.2 M523S Controller PCB schematic

Appendix 1

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52

Dos

Use proper Safety tools and PPEs

Do ensure all the instruments/meters are calibrated.

Do check and ensure all the Tightness of Power and control connections in the
system prior to commissioning of the system in the pre Installation stages.

Put all the Input Output and Battery MCBs or Fuses in ON/Connected condition and
Check continuity between Input (Ph-Ph, Ph-N, and Ph-PE) and Output terminals. It
should be shown as open Condition.

Do check the Input supply for proper voltages/frequency and polarity (line/neutral)
prior to switching the input MCB of the system.

Do check and ensure proper Tightness of Earth/ GND connection to +VE Bus bar in
the system.

Do ensure for proper polarity of DC connection and remove Battery fuses before
connecting the Battery to the DC system then the battery fuses can be inserted back
after proper polarity connected.

Do switch ON the Rectifier Module one by one using the Rectifier Module Input MCB
of Individual Rectifier and observe the indication on the Rectifier Module and read the
parameters on the Controller Display .Also check for load sharing parameters by
each rectifier on controller display.

Do check for all the input and output parameters on the controller display and ensure
the proper voltage /current before switching on the battery and Load.

Do check and regularly record the energy and power readings periodically for the
power consumption drawn by telecom operator.

Do check for Transfer and Retransfer operation by Battery test facility in controller
periodically to know the status of Battery.

Do check and maintain the system clean and Dust free so that in the long run the
moisture and dust do not affect the normal functioning of the system.

Do check for Display calibration by measuring the input and output parameters by
Calibrated meter and verify the respective readings on the controller display. In case
of variation in the displayed reading please contact Emerson Engineer.

Do check for Float /Boost charging action of battery on controller display after a
mains supply failure.

Do check for Alarm log periodically to know and remain updated with the DC system
Status.

Ensure that the temperature sensor installed and functioning properly.

Do maintain the room temperature well within the specified limits.

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53

Donts

Do not switch on the DC system without checking the proper Tightness of all
connections.

Do not switch on the system under input supply abnormal conditions and improper
connections.

Do not switch on the system without proper Earth connections.

Do not terminate the Earth connection to Input Neutral Terminal of DC system.

Do not switch on the system with reverse polarity of DC connections on load and
battery side.

Do not place the system in Dusty and moist environment.

Do not keep the inflammable items near the DC system.

Do not run the DC system under Battery test fail condition since there will be no
battery backup available in case mains supply fails. In such case arrange for
Preventive Battery Maintenance urgently to resolve the problem.

Do not operate the DC system beyond the specified output capacity.

Do not try to switch on the system under fault conditions.

Note: The system might have failed or tripped due to fault conditions.
Please verify the Battery and load parameters before restarting the system.
Do not tamper with the Parameter settings in the controller Display without consulting
Emerson Engineer.

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54

Preventive Maintenance checks for DC Power Plant

Clean the whole DC system with the help of Vacuum cleaner for dust removal.

Check Tightness of all the control & power terminals

Check and Measure

Checking of o/p voltage of all rectifier modules with functionality of all rectifiers.

Checking of float voltage, boost voltage, current limit & other setting of Power Plant.

Checking of all parameters & confirm they are as per requirements.

Checking of regular functioning of controller cards/modules replacing faulty modules.

Checking of alarm generated by power failure & Rectifiers failure from power plants.

Check and Measure load current of Power Plant.

Check controller display voltage & battery terminal should be same.

Check charger current limit as per battery capacity should be 10% of battery backup
in case high, battery charge & discharge the limit shall be 15% with proper consent of
Technical head.

Check Battery Current.

Check the termination of all points should be proper.

Check LVD1 & LVD2 setting.

Check for Battery Health should be carried out quarterly.

Check for the various parameter settings and if required set the settings as per
requirement if found deviated or there is a variation from the original value.

Check for temperature rise checks on the bus bar with the Temperature Gun to
detect the unwanted loads or excess current on the DC system.

Input Voltage (Phase Neutral to Earth)

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Appendix 2

CHECK LIST FOR INSTALLATION INSPECTION AT SITE

Site Name:

Site ID:

1. Check that the system is properly packed & not in damage condition. In Case it is
damage inform customer so as to claim insurance.
2. In case of no damage observed, remove the system from the packing material.
3. Check for any transparent damage, in case of any damage the same should be corrected
before taking up future steps.
4. Check for the mounting platform, if the system has to be installed on the top of battery.
Otherwise grouting provision for free standing installation.
5. Check wires at AC distribution board & DC common points for loose connections.
6. Check all control cable connector are connected at proper connector on the PCB.
7. Check all bus bar joining points for loose connection.
8. Ensure that the earthling potential is less than 2V at the distribution panel.
9. Ensure that the earth resistance is less than 1Ohm.

Recommended Tools

Multi meter
Box type screw driver M6, M8 & M10

Set of spanners, cutter, stripper & plier


Crimping tool up to 120 sq mm

Check

OK

Date:
Place:
Signature:
(Installation Engineer)
Note: To be retained by customer for his record.

Emerson Network Power (India) Private Limited

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Warranty Terms & Conditions:

1. The warranty is applicable to all parts of the power system against manufacturing/ design
defects, except consumable parts susceptible to external operating conditions like surge
protection devices and fuse.
2. The warranty is valid for a period of 18 months from date of supply and 12 months from
date of commissioning, whichever is earlier.
3. The warranty is valid only if:
a) the equipment was selected for use within the manufacturers specifications.
b) is installed / commissioned / serviced by EMERSON NETWORK POWER (I) PVT. LTD.
Trained / Authorized / Technical / Engineer.
c) Operated in accordance with the instructions given in operating / user manual supplied
along with the system.
d) Is operated in an environment and within the temperature limits specified by the
manufacture.
4. Any warranty replaced part will carry the benefit of the unexpired portion of the original
warranty period only.
5. Any fault / damage occurred out of abuse /misuse; lightning, heavy input surges beyond
the limit specified by the manufacturer, over loading, riots, floods etc. and act of god are not
covered under warranty.
6. The warranty is not valid for if the equipment is resold by the customer or if it is bought
from any other source which is not authorized by EMERSON NETWORK POWER (I) PVT.
LTD.
7. Any dispute shall be subjected to jurisdiction of Thane Mumbai only.

NETSURE 702 IC4 Manual

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